In the context of modern industrial production pursuing efficiency, precision, and automation, automatic batching and metering systems have become key technical equipment for ensuring product quality and improving production efficiency due to their highly integrated and intelligent characteristics. This system combines precise material measurement with automated proportioning functions and is widely used in multiple industries such as chemical, food, pharmaceutical, and building materials, providing strong support for enterprises to achieve refined production and digital management.

1、 Definition and core functions of automatic batching and metering system

The automatic batching and metering system is a comprehensive automation system that integrates material storage, transportation, precise measurement, automatic proportioning, and data management. Its core functions are mainly reflected in three aspects: first, precise measurement. Through high-precision sensors and advanced measurement algorithms, the proportioning error of materials is strictly controlled within a very small range. For example, in the preparation of chemical raw materials, the measurement accuracy of some systems can reach ± 0.1%; The second is automated batching. Based on preset formulas, the system can automatically complete the sequential transportation, weighing, and dispensing of various materials, greatly reducing manual intervention and labor intensity; The third is data management and traceability. The system collects, stores, and analyzes real-time data throughout the entire ingredient measurement process, facilitating production management and quality traceability, and providing data support for optimizing production processes for enterprises.

2、 System architecture and working principle

（1） Hardware architecture composition

Material storage unit: mainly includes various types of silos and hoppers, used to store different types of materials. Storage bins are usually made of materials such as stainless steel and carbon steel lined with anti-corrosion coatings based on material characteristics. Some bins are also equipped with level sensors that can monitor material inventory in real time. When the material falls below the set value, an automatic alarm is triggered to remind operators to replenish the material.

Conveyor unit: Common conveying equipment includes screw conveyors, belt scales, pneumatic conveying devices, etc. Spiral conveyors are suitable for closed conveying of powdery and granular materials, such as flour, cement, etc; Belt scales are commonly used for continuous measurement and transportation of bulk materials such as sand, gravel, and coal; Pneumatic conveying devices drive materials through airflow and have the characteristics of long conveying distance and no pollution. They are suitable for materials with high hygiene requirements, such as food raw materials and pharmaceutical excipients.

Measurement unit: It is the core part of the system, mainly composed of weighing sensors, flow sensors, etc. The weighing sensor utilizes the principle of strain to convert the weight of the material into an electrical signal, which is amplified and A/D converted before being transmitted to the control system. Its accuracy can reach 0.05% FS (full range); Flow sensors such as electromagnetic flow meters, mass flow meters, etc. can monitor the flow rate of liquid or gas materials in real time, providing data support for accurate batching.

Mixing unit: including equipment such as mixers and mixers, responsible for thoroughly mixing the prepared materials. According to the material characteristics and production process requirements, different types of mixing equipment can be selected. For example, the double helix cone mixer is suitable for mixing materials with large differences in specific gravity, while the plow blade mixer has a better mixing effect on viscous materials.

Control System: Typically centered around Programmable Logic Controllers (PLCs) or Distributed Control Systems (DCS), paired with Human Machine Interfaces (HMI). PLC is responsible for collecting sensor data, executing control algorithms, and driving actuator actions; HMI provides operators with an intuitive interface for setting formulas, adjusting parameters, monitoring operational status, and other operations. The system can also be connected to the factory's production management system (MES) through network interfaces to achieve data sharing and remote control.

（2） Software system functions

Formula management module: supports multiple formula storage, can quickly call different formulas according to production needs, and can perform operations such as adding, modifying, and deleting formulas. For example, food companies can store ingredient formulas for hundreds of different products, which can be easily accessed with just one click when switching production tasks, improving production flexibility.

Real time monitoring and alarm module: Real time display of parameters such as material flow rate, weight, and equipment operation status. When abnormal situations such as material ratio deviation, equipment failure, and material blockage occur, the system immediately issues sound and light alarms and displays specific fault information on the HMI for operators to handle in a timely manner.

Data statistics and analysis module: automatically records information such as the time, type, quantity, and operator of each ingredient, and generates production reports and statistical charts. By analyzing historical data, production processes can be optimized, material losses can be reduced, and equipment utilization can be improved.

3、 Typical application scenarios

（1） Food and beverage industry

In food processing and production, automatic ingredient metering systems are widely used in the production of baked goods, seasonings, beverages, and other products. For example, on the bread production line, the system precisely controls the ratio of flour, sugar, yeast, oil and other raw materials to ensure consistency in bread taste and quality; In the beverage filling process, quantitative filling of beverages is achieved through the combination of flow meters and weighing sensors. The capacity error of each bottle is controlled within ± 1%, meeting the strict requirements of the market for product specifications.

（2） Chemical industry

The precision requirements for raw material ratio in chemical production are extremely high, and automatic batching and metering systems play an important role in fields such as coatings, rubber, plastics, etc. Taking the production of positive electrode materials for lithium batteries as an example, the system uses high-precision weighing and measurement to accurately control the proportion of raw materials such as lithium iron phosphate and graphite, ensuring the stability of battery performance; In paint production, automatic blending of different colors and compositions of paint improves production efficiency and product quality.

（3） Building materials industry

In concrete mixing plants and dry powder mortar production, the automatic batching and metering system achieves precise metering and automated proportioning of various materials such as sand and gravel, cement, fly ash, additives, etc. The system automatically adjusts the dosage of each material according to the grade requirements of concrete or mortar, ensuring that product strength and other performance indicators meet the standards, while improving production efficiency and reducing labor costs.

4、 Technological advantages and development trends

The automatic batching and metering system has significant technical advantages compared to traditional manual batching methods. High precision measurement ensures the stability of product quality, automated operations reduce human error and labor intensity, and data management functions enhance the production management level of enterprises. In addition, the fully enclosed design of the system can effectively prevent material leakage and dust flying, which meets environmental protection requirements.

In the future, automatic batching and metering systems will develop towards intelligence, integration, and green direction. In terms of intelligence, by introducing artificial intelligence algorithms and machine learning technology, adaptive batching, fault prediction and diagnosis can be achieved; In terms of integration, functions such as metering, conveying, and mixing will be further integrated to reduce equipment footprint and improve overall system performance; In terms of greening, optimize system design, reduce energy consumption, use environmentally friendly materials, and achieve sustainable development.